A ply wire sensor system is provided for a tire carcass ply in a green tire carcass having a toroidal shape, the tire carcass ply having a plurality of spaced apart ply wires extending across the toroidal shape. The sensor system includes a wire sensor mounted in close proximity with the tire carcass ply, the wire sensor detecting the presence of a proximal ply wire; and means for establishing relative movement between the wire sensor and the tire carcass whereby the plurality of spaced apart ply wires are sequentially placed into proximity with the wire sensor. The wire sensor generates sequential data indicative of at least one ply wire parameter of the plurality of spaced apart ply wires.